steering FORD SIERRA 1992 2.G Cooling And Air Conditioning Systems Workshop Manual

System type
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
thermo-viscous fan, thermostat, and expansion tank
CVH and DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with belt-driven coolant pump, crossflow radiator,
electric fan, thermostat, and expansion tank
Thermostat
Nominal temperature rating (fully open):
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190º F)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100ºC (212ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102ºC (216ºF)
Opening temperature:
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88ºC (190ºF)
CVH (R6A type) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 to 89ºC (185 to 192ºF)
Expansion tank cap opening pressure
SOHC models:
Up to 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 to 1.1 bar (12 to 16 lbf/in2)
From 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
CVH models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.25 bar (15 to 18 lbf/in2)
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.4 bar (15 to 20 lbf/in2)
Coolant mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
System capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
Drivebelt tensions
Air conditioning system compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection at the midpoint of the belt’s longest run
under firm thumb pressure
Coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm (0.4 in) deflection midway between coolant pump and
alternator (or power steering pump) pulleys under firm thumb pressure
Chapter 3
Cooling, heating and air conditioning systems
Air conditioning system - component renewal . . . . . . . . . . . . . . . . . .21
Coolant pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .9
Coolant pump/alternator drivebelt(s) - checking, renewal and
tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Coolant pump/alternator drivebelt tensioner (DOHC models with
power steering) - removal and refitting . . . . . . . . . . . . . . . . . . . . . .11
Cooling fan switch - removal and refitting . . . . . . . . . . . . . . . . . . . . .14
Cooling system - draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cooling system - filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cooling system - flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electric cooling fan - removal and refitting . . . . . . . . . . . . . . . . . . . . .13
Expansion tank and coolant level sensor - removal and refitting . . . .15General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Heater controls - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .17
Heater motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .20
Heater unit - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Heater unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Radiator - inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Radiator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Temperature gauge sender - removal and refitting . . . . . . . . . . . . . .16
Thermostat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Thermostat - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Thermo-viscous cooling fan (SOHC models) - removal and refitting .12
3•1
Specifications Contents3
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

36Tighten the coolant pump securing bolts,
and where applicable the pump pulley
securing bolts, to the specified torque.
37On completion, refill the cooling system.
Refer to Chapter 1, Section 21.
Removal
1Remove the alternator drivebelt.
2Loosen the alternator lower mounting
through-bolt, then remove the alternator
upper mounting bolt and swing the alternator
away from the engine.
3Unscrew the central securing bolt, and
withdraw the drivebelt tensioner assembly
(see illustration).
Refitting
4Commence refitting by positioning the
tensioner on the cylinder block, ensuring that
the lug on the rear of the tensioner bracket
engages with the corresponding hole in the
cylinder block. Tighten the securing bolt.
5Swing the alternator into position, to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensionerassembly. Refit the upper mounting bolt, and
tighten the upper bolt and lower through-bolt.
6Fit the drivebelt by reversing the removal
procedure, and release the tensioner to
tension the drivebelt.
7Observe the tensioner indicator, which
should be central in its slot (see illustration).
Removal
1Disconnect the battery negative lead.
2Remove the four retaining clips and
unscrew the two retaining screws, then
withdraw the upper section of the fan shroud
(see illustrations).
3The cooling fan hub nut must now be
unscrewed from the coolant pump drive
flange. A thin cranked 32.0 mm (1.25 in AF)
spanner with a jaw thickness not exceeding
5.0 mm (0.2 in) will be required (see
illustration). Alternatively, if two of the
coolant pump pulley bolts are removed, a
normal thickness spanner can be used.Note
that the fan hub nut has a left-hand thread, (ie
it is undone in a clockwise direction.) If the
pulley turns as the nut is undone, remove the
drivebelt, and clamp an old drivebelt round
the pulley to restrain it, using self-locking
pliers. Tap the spanner with a mallet if
required to remove the nut.4If required, the fan blades can be separated
from the fan hub by unscrewing the four
securing bolts.
Refitting
5Refitting is a reversal of removal, but where
applicable, take care not to overtighten the
bolts securing the fan blades to the fan hub,
as thread damage may require the whole unit
to be renewed. Where applicable, refit and
tension the drivebelt.
CVH models
1Disconnect the battery negative lead.
Unclip the wiring connector from the fan
motor then unscrew the retaining nuts and
washers. Withdraw the fan shroud and
cooling fan assembly (see illustration).
2To remove the fan blades, prise the
securing clip from the end of the motor shaft
(see illustration).
3The motor can be separated from the fan
shroud by unscrewing the three securing nuts
and bolts.
4Where two cooling fans are fitted, both fans
are secured to the fan shroud in the same
manner.
5Refitting is a reversal of removal, but when
refitting the fan blades, ensure that the
direction of rotation arrow faces away from
the motor, towards the radiator.
13Electric cooling fan -removal
andrefitting
12Thermo-viscous cooling fan
(SOHC models) - removal and
refitting
11Coolant pump/alternator
drivebelt tensioner (DOHC
models with power steering)
- removal and refitting
10Coolant pump/alternator
drivebelt(s) - checking, renewal
and tensioning
Cooling, heating and air conditioning systems 3•7
3
12.2a Remove the retaining clips followed
by the screws . . .
13.1 Withdrawing the fan shroud and
cooling fan assembly
12.3 Modified spanner required for
removing the thermo-viscous cooling fan
X = 25.0 mm (1.0 in)Y = 12.0 mm (0.5 in)12.2b . . . and withdraw the upper section
of the fan shroud
11.7 Alternator/coolant pump drivebelt
tensioner indicator position
Inset shows tensioner at maximum
adjustment11.3 Withdrawing the coolant
pump/alternator drivebelt tensioner
assembly. Note lug (A) on tensioner which
engages with hole (B) in mounting bracket

2With the engine cold, slowly unscrew the
expansion tank cap to release any remaining
pressure from the cooling system, then refit
the cap.
3Disconnect the wiring from the sender
terminal (see illustrations).
4Unscrew and remove the sender, and
temporarily plug the aperture.
Refitting
5Refitting is a reversal of removal, but smear
a little sealing compound on the sender unit
threads before fitting.
6On completion, check and if necessary top-
up the coolant level.
Removal
1Disconnect the battery negative lead.
2Remove the securing screws and unclip the
lower and upper steering column shrouds.
3Remove the four securing screws and
withdraw the instrument panel surround. Note
that the bottom right-hand screw is covered
by a plastic panel which must be prised out.
4Remove the passenger side lower facia
panel.
5Where necessary for improved access,
detach the two vent hoses from the left-hand
side of the heater, then detach the lower ends
of the two control cables from the heater by
removing the retaining screws (see
illustration).
6Unscrew the three securing screws, and
remove the heater control panel by sliding it
through the facia panel and withdrawing it
downwards. Disconnect the wiring from the
control panel illumination bulb.
7If necessary, the bulb can be removed with
its holder.
Refitting
8Refitting is a reversal of removal, bearing in
mind the following points.
9When reconnecting the wiring to the control
panel illumination bulb, wrap insulating tapearound the wiring loom over a length of
approximately 330.0 mm (13.0 in) starting
from the bulbholder. Route the loom, ensuring
that it is located in the two retaining clips,
bend it over and secure it to the bulbholder
with insulating tape as shown (see
illustration). This procedure will prevent the
wiring loom from chafing against the heater
control levers.
10When reconnecting the control cables to
the heater, move the control levers on the
control panel to the fully up position, then
attach the cables to the clips on the heater.
The cable ends should project from the clips
by between 0 and 4.0 mm (0 and 0.16 in). The
cables are adjusted automatically by moving
the control levers fully downwards. It is
possible that considerable resistance may
have to be overcome when moving the control
levers.
Removal
1Disconnect the battery negative lead.
2If the coolant is still hot, release the
pressure in the system by slowly unscrewing
the expansion tank cap. Place a thick rag over
the cap to prevent scalding as the pressure is
released.
3Note the location of the two heater hoseson the engine compartment bulkhead, then
disconnect and plug them (see illustration).
Alternatively, the hoses can be secured high
enough to prevent the coolant from draining.
4To prevent unnecessary spillage of coolant
when the heater unit is removed, blow into the
upper heater pipe until all the coolant has
been expelled through the lower pipe.
5Remove the two securing screws and
withdraw the heater pipe cover from the
bulkhead (see illustration). Recover the
gasket.
6Working inside the vehicle, remove the
passenger side lower facia panel.
7Disconnect the ends of the two control
cables from the heater by removing the two
retaining screws.
8Detach the five vent hoses from the heater.
9Unscrew the two mounting bolts, and move
the heater to the rear until the pipes are clear
of the bulkhead, then withdraw the heater to
the left. If necessary, remove the lower facia
bracket (see illustration).
Refitting
10Refitting is a reversal of removal, but
adjust the control cables by moving the levers
on the control panel to the top and then the
bottom stops. Considerable resistance may
be encountered when moving the levers
towards the bottom stops, which should be
overcome.
11On completion, top-up the coolant level.
18Heater unit - removal and
refitting
17Heater controls - removal and
refitting
Cooling, heating and air conditioning systems 3•9
3
18.3 Location of heater hoses on engine
compartment bulkhead18.9 Withdrawing the heater18.5 Heater pipe cover
17.9 Heater control panel illumination bulb
wiring loom correctly routed17.5 Heater control cable lower end fittings
(arrowed)